Food Product Packaging And Method For Producing Food Product Packaging

ABSTRACT

A food product packaging and method of producing the same is provided for containing rigid food products. The packaging includes a tray having at least one receptacle, rigid food products housed in the receptacle and a removable flexible film secured to the tray and enclosing the receptacle. The receptacle is shaped to enable the rigid food products to slide into and be positioned in the receptacle in an orientation that is generally parallel to the bottom wall thereby reducing the chances of the food products breaking in the receptacle and reducing the chances of the food products puncturing the flexible film.

BACKGROUND

Consumers are looking for products containing food for snacking purposesand for on-the-go consumption. Manufacturers of such products arelooking for food product packaging that is consumer friendly andmanufacturing friendly to reduce breakage of the food.

SUMMARY

This invention relates to a package for containing rigid food products.The package includes a tray having at least one receptacle. Thereceptacle has a bottom wall and has a shape to enable rigid foodproducts to slide toward the bottom wall in an orientation that isgenerally parallel to the bottom wall to minimize the food productsbeing broken in the receptacle. The receptacle including a wall with atleast one radius of curvature. The package including a removableflexible film secured to the tray and enclosing the receptacle. Theoccurrences of the rigid food products puncturing the flexible film isreduced due to the shape of the receptacle.

This invention relates to a food product packaging for containing minicrackers. The packaging includes a tray having at least one receptacle,the receptacle having a shape defined at least in part by a curved walland a bottom wall. The packaging includes a plurality of rigid minicrackers housed in the receptacle, the mini crackers having a width anda length dimension of 1.0 inches or less. The packaging includes aremovable flexible film removable secured to the tray and enclosing thereceptacle. The curved wall has a radius of curvature of at least about0.35 inches so that the shape of the receptacle enables the minicrackers to be positioned in the receptacle in an orientation that isgenerally parallel to the bottom wall thereby reducing the occurrencesof the mini crackers breaking in the receptacle and thereby reducing theoccurrences of the mini crackers puncturing the flexible film. Thesedimension can change based on the receptacle depth and cracker size.

The invention relates to a method for filling and for enclosing a traycontaining mini crackers. The method including the steps of providing atray have a receptacle, the receptacle defined at least in part by acurved wall adjacent a bottom wall so as to define a shape of thereceptacle, dropping mini crackers into the receptacle, the shape of thereceptacle enables the mini crackers to drop into and slide in thereceptacle toward the bottom wall in an orientation generally parallelto the bottom wall and enclosing the receptacle with a flexible filmwherein the occurrences of the mini crackers puncturing the flexiblefilm is reduced due to the shape of the receptacle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tray of the present invention;

FIG. 2 is a top view of the tray;

FIG. 3 is a side view of the tray;

FIG. 4 is a sectional view taken along lines 4-4 of FIG. 2;

FIG. 5 is a perspective view of the tray with food products;

FIG. 6 is a perspective view of the tray containing food products with aflexible film secured thereon;

FIG. 7 is a perspective view of a portion of a manufacturing line formanufacturing the food product packaging;

FIG. 8 is a perspective view of another portion of the manufacturingline;

FIG. 9 is a perspective view of square food products entering the tray;

FIG. 10 is a perspective view of the square food products settled in thetray;

FIG. 11 is a perspective view of circular food products entering thetray;

FIG. 12 is a perspective view of the circular food products settled inthe tray; and

FIG. 13 is a top view of various shapes of food products.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of constructions and the arrangement of components set forthin the following description or illustrated in the drawings. Theinvention is capable of other embodiments and of being practiced or ofbeing carried out in various ways.

DETAILED DESCRIPTION

Referring to FIGS. 1-4, there is shown a tray 10 that is a component ofthe food product packaging 12 (FIG. 7) of the present invention. Thetray 10 is preferably semi-rigid and manufactured from an approveddirect food contact thermoformed semi-rigid material such as APET, PVCor the like. The tray 10 includes a planar top surface 14 and two tabs16 adjacent the top surface 14. The tray 10 includes at least onereceptacle 20 for containing a food product, as will be discussed inmore detail below. As shown in the drawings, the tray 10 includes tworeceptacles 20 and 22. It should be noted that any number of receptaclescan be utilized.

The receptacle 20 defines a shape 24 that is advantageous for receivingand for containing the food products. The receptacle 20 includes asquared off end 26 at a draft angle up to 5 degrees to a pointed end 28.The pointed end 28 includes a wall 30 at a draft angle of about 45degrees.

The receptacle 20 includes a first wall 32 extending from the topsurface 14. Preferably, wall 32 is perpendicular to the top surface 14.Optionally, adjacent the wall 32 is a step-down 34 that providesrigidity to the tray 10. A curved wall 36 is adjacent the step-down 34and intersects with a bottom wall 38. The curved wall 36 has a specificradius of curvature R.

Turning now to FIG. 5, tray 10 is shown with food products 40 in thereceptacle 20. The receptacle 20 is suitably configured to contain rigidfood products such as mini crackers. The mini crackers preferably have awidth and a length dimension of one inch or less and can be of anygeometry such as square or triangular. The mini crackers may includesuch food as crackers, chips, pretzels and like rigid food products.Preferably, the receptacle 20 is sized to accommodate between 10 and 35mini crackers.

If the tray 10 includes more than one receptacle, the second receptacle22 may contain the same food products 40 as in the first receptacle 20,different food products than in the first receptacle 20, or othermaterials such as utensils, napkins and the like. As shown in FIG. 5,the second receptacle 22 includes cubes of cheese 42.

As shown in FIG. 6, a flexible film 44 is used as a lidding film toenclose the receptacle 20. The flexible film 44 is preferably a materialmade of a barrier non-forming flexible film such as polyester or nyloncontaining PET/Adhesive/EVA barrier sealant containing EVOH. Theflexible film 44 is removed by the consumer at one of the tabs 16 toenable access to the food products 40 therein.

Turning now to FIGS. 7 and 8, a portion of the manufacturing line 50 forproducing the food product packaging 12 is shown. A conveyor 52transports trays 10 to a scale (not shown) and a funnel 54. The funnel54 releases a predetermined weight of food products 40 into thereceptacle 20 such as 0.5 to 1.5 ounces. The funnel 54 preferable has ageometry that contours to the shape 24 of the receptacle 20. After beingfilled with food products 40, each tray 10 is transported on theconveyor 52 across a vibratory station 56 to further settle the foodproducts 40 in the receptacle 20 if necessary. Thereafter, the flexiblefilm 44 is applied to the top surface 14 of the tray 10 at sealingstation 58 using time, temperature and pressure as is known in the art.

The shape 24 of the receptacle 20 is designed to enable the rigid foodproducts 40 to drop from the funnel 54 and slide to the bottom wall 38of the receptacle 20 into an orientation so as to by lying flat on thebottom wall 38 and not to be standing up to potentially puncture theflexible film 44 when the flexible film 44 is being secured to the topsurface 14. The shape 24 of the receptacle 20 is also designed tominimized breakage of the rigid food products 40 in production andduring distribution. To enable these functions, the tray 10 includes thecurved wall 36 with a specific radius of curvature R. For rigid foodproducts 40 having a length and a width dimension of one inch or less,the radius of curvature R is preferably about at least 0.35 inches. Thecurved wall 36 enables the food products 40 to slide to the bottom wall38 of the receptacle and not end up in the receptacle 20 in an uprightorientation.

For example, see FIG. 9 showing square crackers 40 after entering thetray 10 and extending above the top surface 14 and FIG. 10 wherein theshape of the receptacle 20 enables the square crackers 40 to slide intothe receptacle 20 in an orientation lying flat and not to be extendingabove the top surface 14 to thereby minimize the flexible film beingpunctured thereafter and to thereby minimize breakage of the squarecrackers 40 in production and distribution.

For example, see FIG. 9 showing circular crackers 40 after entering thetray 10 and extending above the top surface 14 and FIG. 10 wherein theshape of the receptacle 20 enables the circular crackers 40 to slideinto the receptacle 20 in an orientation lying flat and not to beextending above the top surface 14 to thereby minimize the flexible filmbeing punctured thereafter to thereby minimize breakage of the squarecrackers 40 in production and distribution.

It is a purpose of the invention that all of the food products 40 aresettled into the receptacle 20 and are not extending above the topsurface 14 thereby interfering with the sealing before the trays 10enter the sealing station 58. If the food products 40 extend above thetop surface 14 before they enter the sealing station 58, then there is ahigh risk of flexible film 44 puncturing. Accordingly, a tray 10 with aspecific radius of curvature R is necessary to enable the food products40 to settle within the receptacle 20 before the flexible film 44 isapplied at the sealing station 58.

Referring to FIG. 13, various shapes for the rigid food products 40 areshown. It should be noted that other shapes can be utilized with thepresent invention.

Various features and advantages of the invention are set forth in thefollowing claims.

1. A package for containing rigid food products comprising: a trayhaving at least one receptacle, the receptacle having a bottom wall andhaving a shape to enable rigid food products to slide toward the bottomwall in an orientation that is generally parallel to the bottom wall tominimize the food products being broken in the receptacle, thereceptacle including a wall with at least one radius of curvature; and aflexible film removably secured to the tray and enclosing thereceptacle, wherein the occurrences of the rigid food productspuncturing the flexible film is reduced due to the shape of thereceptacle.
 2. The package of claim 1 wherein the shape of thereceptacle is defined by a curved wall having a radius of curvature ofabout at least 0.35 inches.
 3. The package of claim 1 wherein the shapeof the receptacle accommodates rigid food products having a width and alength dimension of 1 inch or less.
 4. The package of claim 1 whereinthe receptacle houses between 10 and 35 rigid food products.
 5. Thepackage of claim 3 wherein the receptacle has a height and wherein thereceptacle height is no more than 1.5 times the width or the heightdimension of the rigid food products.
 6. The package of claim 1 whereinthe shape of the receptacle includes a squared off end and a pointedend.
 7. The package of claim 6 wherein the pointed end includes a wallhaving a draft angle.
 8. The package of claim 1 wherein the receptacleincludes a step-up to provide rigidity to the tray.
 9. The package ofclaim 1 wherein the tray is semi-rigid.
 10. A food product packaging forcontaining mini crackers comprising: a tray having at least onereceptacle, the receptacle having a shape defined at least in part by acurved wall and a bottom wall; a plurality of rigid mini crackers housedin the receptacle, the mini crackers having a width and a lengthdimension of 1.0 inches or less; and a flexible film removably securedto the tray and enclosing the receptacle, wherein the curved wall has aradius of curvature of at least about 0.35 inches so that the shape ofthe receptacle enables the mini crackers to be positioned in thereceptacle in an orientation that is generally parallel to the bottomwall thereby reducing the occurrences of the mini crackers breaking inthe receptacle and thereby reducing the occurrences of the mini crackerspuncturing the flexible film.
 11. The packaging of claim 10 wherein thereceptacle houses between 10 and 35 mini crackers.
 12. The packaging ofclaim 10 wherein the receptacle has a height and wherein the receptacleheight is no more than 1.5 times the width or the height dimension ofthe mini crackers.
 13. The packaging of claim 10 wherein the shape ofthe receptacle includes a squared off end and a pointed end.
 14. Thepackaging of claim 10 wherein the pointed end includes a wall having adraft angle.
 15. The packaging of claim 10 wherein the tray issemi-rigid and wherein the receptacle includes a step-up to providerigidity to the tray.
 16. The packaging of claim 10 wherein the at leastone receptacle is two receptacles, and wherein the second receptaclecontains cheese.
 17. A method for filling and for enclosing a traycontaining mini crackers comprising the steps: providing a tray have areceptacle, the receptacle defined at least in part by a curved walladjacent a bottom wall so as to define a shape of the receptacle;dropping mini crackers into the receptacle, the shape of the receptacleenables the mini crackers to drop into and slide in the receptacletoward the bottom wall in an orientation generally parallel to thebottom wall; and enclosing the receptacle with a flexible film whereinthe occurrences of the mini crackers puncturing the flexible film isreduced due to the shape of the receptacle.
 18. The method of claim 17wherein the mini crackers are dropped into the receptacle using a funnelhaving an opening with a geometry similar to the shape of thereceptacle.
 19. The method of claim 17 wherein the shape of thereceptacle is defined by a curved wall having a radius of curvature ofat least about 0.35 inches and wherein the shape of the receptacleaccommodates mini crackers having a width and a length dimension of 1inch or less and wherein the receptacle houses between 10 and 35 minicrackers.
 20. The method of claim 17 and further including the step ofvibrating the tray after the dropping step and before the enclosingstep.